Identifying voltage to prevent motor integrated circuit damage

ABSTRACT

A motor control system, in some embodiments, comprises: a voltage divider circuit having an output node, a voltage on said output node representing a desired motor rotation direction; control logic configured to receive an indication of said voltage; and a motor controller coupled to the control logic, wherein, if said indication of the voltage on the output node falls outside of a predetermined range, the control logic is configured to issue a motor stop signal to the motor controller indicating that at least one resistor of the voltage divider circuit is defective or is missing from the voltage divider circuit.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of the earlier U.S.Utility Patent Application to Ogawa entitled “Identifying VoltageDivider Defects to Prevent Motor Integrated Circuit Damage,” applicationSer. No. 15/186,050, filed Jun. 17, 2016, now pending, the disclosure ofwhich is hereby incorporated entirely herein by reference.

BACKGROUND

Certain motors, such as those used to power car seat cooling fans, aredesigned to rotate in both clockwise and counter-clockwise directions.The direction in which such a motor is rotating at any given time iscontrolled by an input pin on the motor integrated circuit (IC),sometimes known as the SET pin. Typically, applying a SET pin voltagethat is below a particular threshold causes the motor to spin in onedirection, and applying another SET pin voltage that is above thatthreshold causes the motor to spin in the other direction.

The SET pin of the motor IC is often coupled to a voltage dividercircuit that provides an appropriate voltage to the SET pin. The voltagedivider circuit contains one or more resistors, sometimes called“bleeder resistors.” One or both of these resistors can become defectiveor become detached from the voltage divider circuit—for example, due toexcessive jostling or external vibration. When this occurs, themotor—which is rotating in one direction—may immediately begin to rotatein the opposite direction. This abrupt change in rotational directiondraws a significant current through the motor IC, thus damaging themotor IC.

SUMMARY

At least some of the embodiments disclosed herein are directed to motorcontrol system, comprising: a voltage divider circuit having an outputnode, a voltage on said output node representing a desired motorrotation direction; control logic configured to receive an indication ofsaid voltage; and a motor controller coupled to the control logic,wherein, if said indication of the voltage on the output node fallsoutside of a predetermined range, the control logic is configured toissue a motor stop signal to the motor controller indicating that atleast one resistor of the voltage divider circuit is defective or ismissing from the voltage divider circuit. At least some of theseembodiments may be supplemented using one or more of the followingconcepts, in any order and in any combination: further comprising ananalog-to-digital converter (ADC) positioned between said output nodeand said control logic; wherein said indication of the voltage is one ofa predetermined number of digital bit values output by said ADC based onthe voltage on said output node; wherein said predetermined number issixteen; wherein the control logic issues the motor stop signal if saidindication of the voltage is one of the two highest or one of the twolowest of said sixteen digital bit values when the sixteen digital bitvalues are sorted in ascending order; wherein said indication of thevoltage is an analog voltage or a digital bit value; wherein the motorcontroller controls a car seat cooling fan in accordance with said motorstop signal; wherein, if said indication falls within said predeterminedrange, the control logic issues a directional signal to the motorcontroller that indicates whether a motor should rotate clockwise orcounter-clockwise; wherein said predetermined range is the middle 75% ofa defined set of possible values of said indication when said possiblevalues are sorted in ascending order.

At least some embodiments are directed to a computer-readable mediumcomprising code, which, when executed, causes a processor to: receive anindication of a voltage present on an output node of a voltage dividercircuit, said voltage represents a desired motor rotation direction;determine whether said indication of the voltage falls outside apredetermined range; and issue a motor stop signal to a motor controllerif said indication of the voltage falls outside the predetermined range,wherein said motor stop signal represents that at least one resistor ofthe voltage divider circuit is defective or missing. At least some ofthese embodiments may be supplemented using one or more of the followingconcepts, in any order and in any combination: wherein said voltage onthe output node is configured to range between 0 and 5 Volts, andwherein said indication of the voltage on the output node is a digitalbit value selected from a range between 0000 and 1111, inclusive;wherein each digital bit value in said range of digital bit values isassigned to a corresponding analog voltage group, and wherein eachanalog voltage group falls within a range of possible voltages on saidoutput node; wherein said predetermined range is the middle 75% of adefined set of possible values of said indication; wherein the motorcontroller is a car seat cooling fan motor controller.

At least some embodiments are directed to a method for controlling amotor, comprising: obtaining an indication of a voltage present on avoltage divider circuit output node; determining whether said indicationfalls outside a predetermined range; issuing a motor stop signal if saidindication of the voltage falls outside the predetermined range, saidmotor stop signal represents that at least one resistor of the voltagedivider circuit is defective or missing; and stopping a motor based onthe motor stop signal. At least some of these embodiments may besupplemented using one or more of the following concepts, in any orderand in any combination: further comprising quantizing said voltage onthe voltage divider circuit output node to obtain said indication;wherein said predetermined range corresponds to the middle 90% of adefined set of digital bit values; further comprising rotating saidmotor in a direction determined using said indication; wherein saidmotor is a car seat cooling fan motor; wherein said indication isselected from a group of sixteen digital bit values.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of a car seat containing a car seat coolingfan.

FIG. 2 is a block diagram of a motor system.

FIG. 3 is a block diagram of a motor integrated circuit (IC).

FIG. 4 is a block diagram of control logic within a motor IC.

FIG. 5 is a table that cross-references analog SET pin voltages withcorresponding digital bit values.

FIG. 6 is a flow diagram of a method for stopping a motor to prevent ICdamage when a voltage divider circuit has been compromised.

The specific embodiments given in the drawings and detailed descriptiondo not limit the disclosure. On the contrary, they provide thefoundation for one of ordinary skill to discern the alternative forms,equivalents, and modifications that are encompassed together with one ormore of the given embodiments in the scope of the appended claims. Theterm “couple” and variants thereof, as used herein, indicate a direct orindirect connection.

DETAILED DESCRIPTION

Disclosed herein is a technique for protecting a motor integratedcircuit (IC) from damage resulting from a compromised voltage dividercircuit at the SET pin (i.e., the pin controlling motor rotationdirection) of the IC. The technique entails monitoring the voltage thatthe voltage divider circuit provides to the SET pin and, when thevoltage falls outside the scope of a predetermined range, issuing a stopsignal to the motor controller that stops motor rotation.

FIG. 1 is a perspective view of a car seat 100. The fan 102 may operateto cool a person resting in the car seat 100 by causing air to circulatewithin or adjacent to the material (e.g., leather, fabric) with whichthe car seat 100 is upholstered. The fan 102 is not limited toinstallation in cars and may be installed in any type of vehicle,including pickup trucks, sport utility vehicles, crossovers, freighttrucks, helicopters, airplanes, trains, and the like. The fan 102contains a motor that is designed to rotate in both the clockwise andcounter-clockwise directions. As described below, the motor system offan 102 implements a technique that protects the motor IC from the typeof abrupt rotation reversal damage described above. The embodimentsdescribed herein are not limited to implementation in car seat coolingfans; instead, the embodiments may be implemented in any applicationthat entails the use of a motor that switches rotational direction.

FIG. 2 is a block diagram of a motor system 198 in which the motorIC-preserving technique is implemented. The motor system 198 may behoused within any suitable device that requires a motor, such as the carseat cooling fan 102 shown in FIG. 1. The motor system 198 comprises amotor IC 200; a motor driver 202; a motor 204; a SET pin input node 206;a pulse width modulation (PWM) pin input node 208; one or more outputsignals 210 of the motor IC 200; and an output node 212 of the motordriver 202. The motor IC 200 controls various facets of the motor driver202 and, by extension, of the motor 204. For instance, and withoutlimitation, the SET pin of the motor IC 200 (which may be labeleddifferently, depending on the IC) controls the direction in which themotor 204 rotates. A SET pin voltage that is within a specific range maycause the motor 204 to rotate clockwise, and a SET pin voltage that iswithin a different range may cause the motor 204 to rotatecounter-clockwise. Other SET pin schemes are contemplated. Similarly,the PWM pin of the motor IC 200 may control the duty cycle of the motor204, regardless of the rotational direction. Additional input pins maybe provided on the motor IC 200 to control other facets of the operationof motor 204. Depending at least in part on the inputs provided to theinput pins of the motor IC 200, the motor IC 200 generates one or moreoutput signals 210 that determine the behavior of the motor driver 202.The motor driver 202, in turn, drives the motor 204 in accordance withthe output signals received from the motor IC 200, such as with aspecific rotational direction and with a specific duty cycle.

FIG. 3 is a more detailed block diagram of the motor IC 200 and alsodepicts a voltage divider circuit 300 coupled to the SET pin input node206. The motor IC 200 includes an analog-to-digital converter (ADC) 312;control logic 314; PWM logic 315; an OR logic gate 316; and a motorcontroller 318. The ADC 312 may be any suitable type of converter, suchas a sigma-delta converter, that can convert analog input signals on theSET pin input node 206 to corresponding digital bit values. The controllogic 314 includes any suitable type of hardware, software and/orfirmware that can receive the digital bit values from the ADC 312 anddetermine, based on those digital bit values, whether the motorcontrolled by the motor IC 200 should be stopped due to a compromisedvoltage divider circuit 300. FIG. 4 is a block diagram of the controllogic 314. The control logic 314 includes a processor 400 that couplesto storage 402 (e.g., random-access memory (RAM) or read-only memory(ROM)) via node 406. The storage 402 stores code 404 (e.g., softwareand/or firmware) that can be executed by the processor 400 to performsome or all of the functions attributed herein to the control logic 314.The processor 400 receives inputs on node 320 and provides outputs onnode 322 (output node 326 is omitted from FIG. 4). The architectureshown in FIG. 4 is merely illustrative. Any suitable architecture thatenables the control logic 314 to perform the functions attributed to itherein may be implemented.

Referring again to FIG. 3, the motor controller 318 comprises anysuitable hardware (e.g., a processor), software and/or firmware that arenecessary to control the motor driver and, by extension, the motor. ThePWM logic 315 is described below. In some embodiments, the variouscomponents of the motor IC 200 depicted in FIG. 3 are discretecomponents; however, the scope of disclosure is not limited as such, andthe components within the motor IC 200 may be designed as desired aslong as the functionalities described herein are implemented.

The voltage divider circuit 300 includes a voltage source 302 (e.g., 5Volts); a resistor 304 (e.g., 10 kilo Ohms); another resistor 306 (e.g.,10 kilo Ohms); and ground connections 308. The SET pin input node 206 ispositioned between the resistors 304 and 306, as shown, and it isalternatively referred to as the output node of the voltage dividercircuit 300.

Voltage divider circuits are commonly found in many motor systems. Onefunction of such circuits is to ensure the proper provision of a SET pinvoltage so that the motor rotates in a desired direction. As explainedabove, however, in many instances one or both of the resistors in thedivider circuit may become defective or may become detached from thevoltage divider circuit. In such instances, the signal provided on theSET pin input node of the motor IC will cause the motor to immediatelyreverse rotational direction, thus damaging the motor IC. The motor IC200, however, is designed to detect when the voltage divider circuit 300has been compromised in this manner and to issue a motor stop signal tothe motor controller 318, thus preventing the motor from suddenlyreversing rotational direction and, by extension, preventing damage tothe motor IC 200. Accordingly, the operation of the motor IC 200 is nowdescribed.

The analog voltage on the SET pin input node 206 has a range of possiblevalues—for instance, between 0 and 5 V. The ADC 312 quantizes the analogvoltage detected on the node 206 to one of a defined set of digital bitvalues. The precise number of digital bit values in the set varies, but,in at least some embodiments, the analog voltage on the SET pin inputnode 206 is quantized to one of sixteen different digital bit values.The number of possible digital bit values in a given implementation isused to evenly divide the analog voltage range into groups. For example,dividing the analog voltage range of 0 to 5 V by an illustrative sixteendigital bit value possibilities results in sixteen different groupswithin the 0 to 5 V range. The ADC 312 detects the analog voltage onnode 206 and determines to which of these sixteen groups of analogvoltages the detected voltage belongs. After identifying the appropriateanalog voltage group, the ADC 312 generates an output that is thedigital bit value corresponding to the identified analog voltage group.The mapping scheme between analog voltage groups and correspondingdigital bit values may be assigned in any desired manner. However, in atleast some embodiments, the mapping scheme is determined by sorting theanalog voltage groups in ascending order, sorting the defined set ofdigital bit values in ascending order, and correlating the analogvoltage groups and digital bit values that have the same index numbers.

FIG. 5 is a table 500 that illustrates such mapping. Column 502 includesindex numbers 0-15, meaning that the analog voltage detected on the node206 (FIG. 3) is quantized to one of sixteen possible digital bit values.Column 504 lists the possible analog voltage groups. As explained, thesegroups are determined by dividing the possible analog voltage range (inthis instance, 0 to 5 V) by the number of possible digital bit values(in this instance, sixteen). In this example, each analog voltage groupin column 504 has a range of approximately 5V/16=0.31 V. Thus, as shown,index number 0 corresponds to a range of 0 to 0.31 V; index number 1corresponds to a range of 0.32 V to 0.63 V, and so on. As shown, theanalog voltage groups in column 504 are sorted in ascending order,although other orders are contemplated. Column 506 lists a correspondingset of digital bit values. Because the index values in column 502 rangefrom 0 to 15, four bits are required for each digital bit value incolumn 506 (i.e., 2⁴=16). The digital bit values in column 506 aresorted in ascending order, although other orders are contemplated. Inthis way, each of the analog voltage groups in column 504 is mapped tothe adjacent digital bit value in column 506. Thus, for instance, thedigital bit value 0000 is mapped to the analog voltage group 0 to 0.31V; the digital bit value 0111 is mapped to the analog voltage group 2.20to 2.50 V; and the digital bit value 1111 is mapped to the analogvoltage group 4.7 to 5.00 V. Accordingly, if the ADC 312 detects ananalog voltage between 0.64 and 0.94 V (inclusive) on the node 206, itwill quantize that analog voltage to the digital bit value 0010.Similarly, if the ADC 312 detects an analog voltage between 2.82 and3.13 V (inclusive) on the node 206, it will quantize that analog voltageto the digital bit value 1001. Table 500 is merely illustrative, and thescope of disclosure is not limited to the specific mapping scheme,analog voltage groups, defined set of digital bit values, total indexnumber (i.e., sixteen), etc. shown therein. Any and all variations andequivalents are contemplated. Columns 508 and 510 of table 500 aredescribed further below.

Referring again to FIG. 3, the ADC 312 assigns each analog voltagedetected on node 206 to the corresponding digital bit value and outputsthat digital bit value on an output node 320. The digital bit valueoutput on the output node 320 is an “indication” of the analog voltageon the SET pin input node 206. In some embodiments, an ADC 312 might notbe used, and a non-quantized analog voltage may be provided to theoutput node 320. This analog voltage is also considered to be an“indication” of the voltage on the node 206. The remainder of thisdiscussion assumes that the indication on node 320 is a digital bitvalue, but it is understood that analog voltages may be used as well.

The control logic 314 receives the indication of the voltage on the SETpin input node 206 via node 320 and uses the indication to determinewhether to issue a motor stop signal on output node 322. Specifically,the control logic 314 determines whether the indication falls within apredetermined range of indication values—e.g., within the middle 75% ofa defined set of possible values of the indication. For example, if theADC 312 outputs a 4-bit digital bit value, the range of possible valuesis between 0000 and 1111. Thus, when the range of possible digital bitvalues is sorted in ascending order and each digital bit valuerepresents a corresponding analog voltage group from a set of analogvoltage groups sorted in ascending order (as explained above), themiddle 75% includes the values from 0010 to 1101. The bottom 12.5%includes 0000 and 0001, and the top 12.5% includes 1110 and 1111. FIG. 5illustrates this example. As shown in column 506, the range of possiblevalues is from 0000 to 1111, and the middle 75% corresponds to themiddle 12 values (i.e., 0010 to 1101); the bottom 12.5% corresponds tothe bottom two values (i.e., 0000 and 0001); and the top 12.5%corresponds to the top two values (i.e., 1110 and 1111).

Continuing with this example, if the indication received at node 320falls within the middle 75% of possible digital bit values, the controllogic 314 outputs a LOW signal on the output node 322, as shown incolumn 508. This LOW signal indicates that there is no evidence that thevoltage divider circuit 300 has been compromised, and the motor does notneed to be stopped. However, if the indication at node 320 falls outsidethe middle 75% of possible values (i.e., within the bottom 12.5% or top12.5%), the control logic 314 outputs a HIGH signal on the output node322, as shown in column 508. This HIGH signal indicates that the voltagedivider circuit 300 has likely been compromised (due to a substantialincrease in voltage because of a missing ground connection adjacent tonode 206, or due to a substantial decrease in voltage because of amissing connection to the voltage source 302), and the motor should bestopped. This HIGH signal is called a motor stop signal, and the mannerin which it is handled is discussed below. The scope of disclosure isnot limited to issuing a motor stop signal only when the indicationfalls outside of the middle 75% of a defined set of possible indicationvalues. Any desired thresholds may be set to dictate when a particularindication value warrants the issuance of a motor stop signal.

A LOW output on node 322 indicates that the voltage divider circuit 300has not been compromised and that the motor should continue rotating. Insuch cases, the control logic 314 outputs a directional signal on node326 that indicates the direction in which the motor should rotate. Thecontrol logic 314 uses the indication on node 324 to determine thedirection in which the motor should rotate. For example, if theindication is within a first predetermined range, the control logic 314may output a LOW directional signal to indicate clockwise rotation, andif the indication is within a second predetermined range, the controllogic 314 may output a HIGH directional signal to indicatecounter-clockwise rotation. Column 510 of FIG. 5 illustrates thisscheme. Index numbers 2-13, for which a motor stop signal will not beasserted and for which the motor will continue rotating, are dividedinto two groups: index numbers 2-7, which correspond to a LOWdirectional signal in column 510 and thus result in clockwise motorrotation, and index numbers 8-13, which correspond to a HIGH directionalsignal in column 510 and thus result in counter-clockwise rotation. Forindex numbers 0-1 and 14-15, the value of the directional signal isirrelevant, since the motor will be stopped. The threshold between LOWand HIGH directional signals in column 510 may be set as desired and asmay be suitable.

Referring again to FIG. 3, if the signal output on node 322 is HIGH,meaning that the control logic 314 issued a stop motor signal, the ORgate 316 outputs a HIGH signal on output node 324 to the motorcontroller 318. Alternatively, the output of the OR gate 316 may be HIGHif the PWM logic 315 outputs a HIGH signal on node 317. The PWM logic315 comprises any suitable hardware, software and/or firmware that maygenerate a motor stop signal for any reason other than a defect in oneor both of the resistors in the voltage divider circuit 300. If bothinputs to the OR gate 316 are LOW, the output of the OR gate 316 is alsoLOW. The motor controller 318 receives the signal output by the OR gate316 on node 324 and outputs one or more control signals 210 accordingly.The control signals 210 are provided to the motor driver and are used tocontrol the motor. The control signals 210 are not limited to the signaloutput by the OR gate 316. Other signals also may be included as part ofthe control signals 210—for instance, the directional signal 326, thevalue of which is relevant if the node 324 is LOW and the motorcontinues rotating.

FIG. 6 is a flow diagram of a method 600 for stopping a motor to preventIC damage when a voltage divider circuit has been compromised. Themethod 600 begins with detecting an analog voltage from the voltagedivider circuit at the SET pin of the motor IC (step 602). The method600 then comprises converting the analog voltage to a digital bit value(step 604). As explained above, this may be accomplished by identifyingwhich of multiple analog voltage groups the detected voltage belongs to,and then by quantizing the detected analog voltage to the digital bitvalue corresponding to the identified analog voltage group. The method600 next includes determining whether the digital bit value fallsoutside of a predetermined range of digital bit values (step 606). Asexplained, this predetermined range of digital bit values is part of alarger, defined set of possible digital bit values. In some embodiments,the predetermined range may be the middle 75% of the defined set ofpossible digital bit values. In other embodiments, the predeterminedrange may be the middle 95%, the middle 90%, the middle 66%, the middle50%, or some other suitable range. If the digital bit value output bythe ADC falls outside of this predetermined range, the voltage dividercircuit probably is defective (i.e., one or more of the bleederresistors is defective or has become detached). Accordingly, a stopmotor signal is issued, and the motor is stopped (step 608). Otherwise,the method 600 comprises determining whether any other stop motor signalhas been issued—for example, by the PWM logic 315 of FIG. 3 (step 610).If so, the motor is stopped (step 608). Otherwise, the motor will not bestopped, and the method 600 comprises setting the motor direction andother suitable settings (e.g., duty cycle) based on the digital bitvalue (step 612). The method 600 may be modified as desired, includingby adding, deleting, modifying or rearranging one or more steps.

Numerous other variations and modifications will become apparent tothose skilled in the art once the above disclosure is fully appreciated.It is intended that the following claims be interpreted to embrace allsuch variations, modifications and equivalents.

What is claimed is:
 1. A motor control system, comprising: a controllogic configured to receive an indication of a voltage representing adesired motor rotation direction; a motor controller coupled to thecontrol logic; and a logical OR gate having a first input terminalcoupled to the control logic, a second input terminal coupled to a pulsewidth modulation (PWM) logic, and an output terminal coupled to themotor controller; wherein the control logic is configured to issue asignal if the indication of voltage falls within a predetermined range.2. The system of claim 1, wherein the indication of the voltage is apredetermined number of digital bit values output by ananalog-to-digital converter (ADC).
 3. The system of claim 2, wherein thepredetermined number is sixteen.
 4. The system of claim 3, wherein thecontrol logic issues a motor stop signal if the indication of thevoltage is one of the two highest or one of the two lowest of thesixteen digital bit values when the sixteen digital bit values aresorted in ascending order.
 5. The system of claim 1, wherein theindication of the voltage is one of an analog voltage or a quantizeddigital bit value.
 6. The system of claim 1, wherein the motorcontroller is configured to control a car seat cooling fan.
 7. Thesystem of claim 1, wherein, if the indication of the voltage fallswithin a predetermined range, the control logic issues a directionalsignal to the motor controller that indicates whether a motor shouldrotate clockwise or counter-clockwise.
 8. The system of claim 7, whereinthe predetermined range is the middle 75% of a defined set of possiblevalues of the indication when the possible values of the indication aresorted in ascending order.
 9. A motor control system, comprising: acontrol logic configured to receive an indication of a voltagerepresenting a desired motor rotation direction; a motor controllercoupled to the control logic; and a logical OR gate having a first inputterminal coupled to the control logic, a second input terminal coupledto a pulse width modulation (PWM) logic, and an output terminal coupledto the motor controller; wherein the control logic is configured todetermine whether the indication of the voltage falls outside apredetermined range; and wherein the control logic is configured toissue a motor stop signal to the motor controller if the indication ofthe voltage falls outside the predetermined range.
 10. The system ofclaim 9, wherein the indication of the voltage is a digital bit valueselected from a range between 0000 and
 1111. 11. The system of claim 10,wherein each digital bit value in the range of digital bit values isassigned to a corresponding analog voltage group.
 12. The system ofclaim 9, wherein the predetermined range is a middle 75% of a definedset of possible values of the indication.
 13. The system of claim 9,wherein the motor controller is a car seat cooling fan motor controller.14. The system of claim 9, further comprising an analog-to-digitalconverter (ADC) coupled to the control logic.
 15. A method forcontrolling a motor, comprising: receiving an indication of a voltage ata control logic; determining whether the indication of the voltage fallsoutside of a predetermined range; and issuing, through the controllogic, a motor stop signal if said indication of the voltage fallsoutside of the predetermined range; wherein the motor stop signal isprovided to a first input terminal of a logical OR gate which has asecond input terminal coupled to pulse width modulation (PWM) logic andan output terminal coupled to a motor controller.
 16. The method ofclaim 15, further comprising quantizing a voltage to receive theindication of the voltage.
 17. The method of claim 15, wherein thepredetermined range corresponds to the middle 90% of a defined set ofdigital bit values.
 18. The method of claim 15, further comprisingrotating a motor in a direction determined using the indication of thevoltage.
 19. The method of claim 18, wherein the motor is a car seatcooling fan motor.
 20. The method of claim 15, wherein the indication isselected from a group of sixteen digital bit values.